Dissemination DeliverablesD3.1

Deliverable 3.1

Abstract

Deliverable 3.1 presents the geometrical model of the Dot-by-Dot Wire and Arc Additive Manufacturing (WAAM) developed within the CIRCULAR WELD project. Dots’ geometry plays a key role in determining both the welding torch optimal toolpath and the mechanical properties of the final product. In this work an analytical physics-based geometrical model is presented, capable of predicting the geometric characteristics of dot-by-dot additively manufactured bars from the properties of the feedstock material, the welding process parameters and interpass temperature. The proposed model is based on heat transfer and mass conservation and can be applied to different scenarios and materials, being more general with respect to experimental-regressive approaches. An experimental validation on ER70S-6 steel bars was performed on different preliminary tests, showing fair accuracy in predicting bars diameter and height. Validated through 9 specific case studies using measured interpass temperature, the model yielded absolute percentage errors generally below 5%, demonstrating the model's effectiveness in enhancing toolpath definition and process repeatability.

Table of contents

1.    INTRODUCTION

2.    PROPOSED MODEL

3.   PRELIMINARY EXPERIMENTAL VALIDATION

3.1 Discussion

4.    REFINED EXPERIMENTAL VALIDATION

4.1 Discussion

5.    CONCLUSIONS

6.    REFERENCES